Remove/install 2-cylinder compressor

AR13.30-W-0002S

Remove/install 2-cylinder compressor

04.12.2019

Engine

457.9 in model 949

with code MZ8 (Air compressor, 2-cylinder, regulated)

1

Power steering pump

5

Suction pipe

9

Coolant line (feed)

2

Compressed-air line

6

Oil separator

10

Sealing ring

3

Screw

7

Control line

11

Coolant line (return flow)

4

Resonator

8

Compressor

12

Cross plate

8

Compressor

18

Drive gear

19

Sealing rings

20

Sealing ring

 Caution

Risk of injury to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil

Wear protective gloves, protective clothing and safety glasses.
Do not fill engine oil into beverage containers.

AS18.00-Z-0001-01A

 Warning

Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.

Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

 Warning

Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.

Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.
Wear protective gloves, protective clothing and safety glasses.

AS20.00-Z-0001-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Topical note

Notes on coolant

AH20.00-N-2080-01A

Note on calculation of tightening torque when using insertion or socket tools with various effective lengths

AH00.00-P-0015-01CW

Notes on engine oil

AH18.00-N-0101-01HA

 

Remove/install

1

Open engine hood and raise to vertical position

AR88.40-W-1000R

 Installation: Do not close the engine hood until after the leak test.

2

Remove upper cover on cab

AR88.30-W-2301S

3

Partially drain coolant at radiator

AR20.00-W-1142S

 Collect escaping coolant in a clean vessel.

4

Remove front section of front left fender

AR88.10-W-1500RE

5

Remove bracket for front section of front left fender

6

Remove shield on the left on cab

Only for vehicles with body 949.899

AR60.80-W-0003S

7

Remove soundproofing on left

8

Disconnect suction line (5) on resonator (4)

 Installation: Check sealing ring; replace suction line (5) if necessary.

9

Remove screw/bolt (3) and resonator box (4)

 Installation: Check seal; replace if necessary.

10

Completely drain coolant at retarder

Only for vehicles with code BA1 (Performance-optimized Voith retarder)

AR20.00-W-1142S

11

Remove front coolant pipes on retarder

Only for vehicles with code BA1 (Performance-optimized Voith retarder)

AR43.30-W-0002-03S

12

Remove compressed-air line (2) and check for carbonization

 Union nut, compressed air line to fitting

*BA13.30-N-1011-01L

If the compressed-air line (2) is carbonized.



Replace compressed-air line (2). In addition, check compressed-air lines between compressor (8), compressed-air drier and four-circuit protection valve.

If the compressed-air lines between the compressor (8), the compressed-air drier or the four-circuit protection valve are carbonized.



Replace respective compressed-air line.

13

Unfasten coolant line (11)

 Union nut, coolant line to compressor fitting

*BA13.30-N-1010-01L

14

Remove coolant line (9)

 Union nut, coolant line to compressor fitting

*BA13.30-N-1010-01L

15

Unfasten control line (7)

 Banjo bolt, control line to compressor

*BA13.30-N-1006-01L

16

Remove power steering pump (1) on compressor (8) and place to one side

 Do not disconnect steering gear oil lines.

 Bolt, power steering pump to compressor

*BA46.30-N-1001-01ZE

17

Remove cross plate (12) on power steering pump (1) or on compressor (8)

 Installation: Secure cross plate (12) against sliding using grease.

Paste, hot lubrication 1 kg, DBL 6879.20

*BR00.45-Z-1005-06A

18

Remove compressor (8) from timing case

 Remove a screw/bolt through the opening of the oil separator (6) on the timing case at the rear.
Remove the remaining screw/bolt to the front on the compressor (8).
Collect escaping engine oil.

 Installation: Before the compressor (8) is placed on the timing case, insert the long screw/bolts.
When placing the compressor (8), turn the drive gear (18) if necessary.

 Bolt, compressor to crankcase

*BA13.30-N-1001-01L

19

Check drive wheel (18) and drive wheel on camshaft for damage

If the drive wheel (18) on the compressor (8) is damaged.



Replace drive gear (18).

AR13.30-W-7043C

If the drive gear on the camshaft is damaged.



Replace drive wheel or camshaft.

20

Remove sealing rings (19, 20) at compressor (8)

21

Remove compressed-air line (2) fitting and suction line (5) fitting on compressor (8)

Only if compressor (8) was replaced or fitting is leaky.

 Fitting, compressed air line to compressor

*BA13.30-N-1004-01L

 Fitting, suction line to compressor

*BA13.30-N-1005-01L

22

Remove fittings of coolant lines (9, 11) on compressor (8)

Only if compressor (8) was replaced or fitting is leaky.

 Fitting, coolant line to compressor

*BA13.30-N-1008-01L

23

Install in the reverse order

24

Fill in coolant

AR20.00-W-1142S

25

Check engine oil level with oil dipstick or on display, add oil if necessary

 Observe engine oil quality set in maintenance system or Specifications for Operating Fluids.

26

Start engine and perform an engine test run

27

Check compressed air line (2) for leaks

28

Stop engine and check in the area around the compressor (8) by means of visual inspection for leaktightness

29

Check retarder coolant hoses and retarder coolant hoses below on the retarder for leaktightness by means of a visual inspection

Only for vehicles with code BA1 (Performance-optimized Voith retarder)

 Compressor (compressed air system)

Number

Designation

ENGINE 457.9 with CODE MZ8

BA13.30-N-1001-01L

Bolt, compressor to crankcase

Nm

60

 Compressor (compressed air system)

Number

Designation

ENGINE 457.9 with CODE MZ8

BA13.30-N-1004-01L

Fitting, compressed air line to compressor

Nm

80

 Compressor (compressed air system)

Number

Designation

ENGINE 457.9 with CODE MZ8

BA13.30-N-1005-01L

Fitting, suction line to compressor

Nm

80

 Compressor (compressed air system)

Number

Designation

ENGINE 457.9 with CODE MZ8

BA13.30-N-1006-01L

Banjo bolt, control line to compressor

Nm

15

 Compressor (compressed air system)

Number

Designation

ENGINE 457.9 with CODE MZ8

BA13.30-N-1008-01L

Fitting, coolant line to compressor

Nm

30

 Compressor (compressed air system)

Number

Designation

ENGINE 457.9 with CODE MZ8

BA13.30-N-1010-01L

Union nut, coolant line to compressor fitting

Nm

40

 Compressor (compressed air system)

Number

Designation

ENGINE 457.9 with CODE MZ8

BA13.30-N-1011-01L

Union nut, compressed air line to fitting

M22x1.5

Nm

65

M26x1.5

Nm

75

 Power steering pump

Number

Designation

Model 949 with engine 457.9

BA46.30-N-1001-01ZE

Bolt, power steering pump to compressor

Nm

40

Repair materials

Number

Designation

Order number

BR00.45-Z-1005-06A

Paste, hot lubrication 1 kg, DBL 6879.20

A 000 989 76 51